Method of forming a package

ABSTRACT

A method of forming a package is provided and includes providing two laminate edge portions of the package, each of which includes a foil layer between first and second resin layers; and welding together the respective first resin layers at a first position spaced apart from the edges while not welding the respective first resin layers at the edges, wherein the edge portions include edges from which electrode terminals extend such that portions of the electrode terminals are exposed beyond the edges, and wherein the edge portions are between a sealing portion and exposed portions of positive and negative electrode terminals.

RELATED APPLICATION DATA

This application is a continuation of U.S. application Ser. No.15/858,197, filed on Dec. 29, 2017, which application is a divisional ofU.S. application Ser. No. 14/870,703 filed on Sep. 30, 2015, now U.S.Pat. No. 9,871,232 issued on Jan. 16, 2018, which is a continuation ofU.S. application Ser. No. 14/334,208 filed on Jul. 17, 2014, now U.S.Pat. No. 9,178,186 issued on Nov. 3, 2015, which is a continuation ofU.S. application Ser. No. 13/549,116, filed on Jul. 13, 2012, now U.S.Pat. No. 8,871,383 issued Oct. 28, 2014, which is a continuation of U.S.application Ser. No. 11/289,191, filed Nov. 29, 2005, now U.S. Pat. No.8,263,256 issued on Sep. 11, 2012, which claims the benefit of priorityto Japanese Patent Application No. JP 2004-357820 filed in the JapanesePatent Office on Dec. 10, 2004, the entireties all of which areincorporated by reference herein.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to cells, and more particularly, relatesto a cell formed by using a laminate film as an exterior packagingmaterial.

2. Description of the Related Art

In recent years, a great number of portable electronic apparatuses suchas camera-incorporated VTRs (videotape recorders), mobile phones, andlaptop computers have been introduced into the market, and trends towardminiaturization of the portable electronic apparatuses and reduction inweight thereof have been positively pursued. Concomitant with the trendsdescribed above, cells used as power sources of portable electronicapparatuses are rapidly increasing in demand, and in order to realizeminiaturization of the apparatuses and reduction in weight thereof, cellengineering has been requested to reduce the weight and thickness of acell and to enable it to be efficiently accommodated in a limited spaceof a portable electronic apparatus. As a cell capable of satisfying therequests described above, for example, lithium ion cells, which have ahigh energy density and output density, may be mentioned as one of themost preferable cells.

Among the various cells, a cell having a high degree of freedom ofshape, a thin sheet-type cell having a large area, a thin card-type cellhaving a small area, and the like have been desired; however, as long asa related method is employed which uses a metal can as an exteriorpackaging material, it has been difficult to manufacture thin cells.

In order to overcome the problem described above, for example, a cellcontaining a material imparting adhesive properties to an electrolyte,and a cell containing a polymer gel electrolyte have been investigated.In the cells described above, the electrode and the electrolyte aretightly adhered to each other, and hence the contact state therebetweencan be ensured. Accordingly, a thin cell can be manufactured by using anexterior packaging film such as an aluminum laminate film.

Heretofore, as applications of laminate films, for example, food,pharmaceuticals, and films may be mentioned; however, due to expirationdates given to products mentioned above, long-term reliability may notbe always required for the laminate films in many cases. On the otherhand, since secondary cells are used for a long time while charge anddischarge are repeatedly performed, the lamination film is particularlyrequested to have good long-term reliability.

FIG. 1 is a schematic perspective view showing a cell which uses alaminate film as an exterior packaging material. Reference numeral 1indicates a cell packaged in the laminate film. Since the laminate filmhas no electrical conductivity, electrode terminals 2 are necessarilyprovided along a side at which two parts of the laminate film areoverlapped with each other so as to extend outside. In the state asdescribed above, two parts of an interior resin film of the laminatefilm are disposed to face each other, and thermal welding is performedalong a peripheral portion of a cell element, so that air-tight sealingcan be performed. In this case, when the width of the film which issealed by the thermal welding is decreased, a larger cell element can bedesigned, and hence, a cell having a higher capacity can be obtained.

FIG. 2 shows one example of a main structure of a laminate film 10. Ametal foil indicated by reference numeral 11 is provided between a resinfilm 12 and a resin film 13 to form a multilayer film having humidityresistance and insulating properties. As the resin film 12 providedoutside, nylon or polyethylene terephthalate) is used due to its fineappearance, toughness, and flexibility. The metal foil 11 has animportant role of protecting a content packaged in the laminate filmfrom entering moisture, oxygen, and light, and in consideration oflight-weight properties, elongation properties, price, andprocessability, aluminum (Al) has been most widely used. Two parts ofthe interior resin film 13, facing each other, are melted by applicationof heat or ultrasonic sound so as to be welded to each other; hence apolyolefin resin is preferably used, and a cast polypropylene (CPP)resin has been used in many cases. Adhesive layers 14 may be providedbetween the metal foil 11 and the resin films 12 and 13, whenevernecessary.

When a cell element is packaged in the laminate film 10, followed bythermal welding, the inside CPP layer is melted, and adhesion is carriedout. However, a metal of the electrode terminal 2 extending from thecell element has poor adhesion properties to the CPP. Hence, as shown inFIGS. 1 and 3, in order to improve the adhesion to the CPP, resinmaterial is adhered to two surfaces of the electrode terminal 2. Thisresin material is called a sealant 3.

As problems which may arise when an aluminum laminate film is used as anexterior packaging material, for example, since moisture is liable toinfiltrate the cell to cause unfavorable electrolytic chemical reactiontherein, degradation in cell properties may be mentioned. Moisture doesnot infiltrate through an Al layer and mostly infiltrates the interiorresin (CPP) portion.

The amount of infiltrating moisture is proportional to a cross-sectionalarea (cross-sectional area of the CPP layer) of an infiltration path andis reciprocally proportional to the length thereof (sealing width).Accordingly, in order to prevent moisture infiltration, it is necessarythat the thickness of the CPP layer be decreased to decrease thecross-sectional area or that the sealing width, that is, the pathlength, be increased. In view of increase in cell capacity, in order toreduce the amount of infiltrating moisture, it is more preferable thatthe infiltration path be narrowed by decreasing the thickness of the CPPlayer. In this case, since the thickness of the laminate film itself isdecreased, the size of an entire cell can be designed larger, and as aresult, the capacity thereof can be increased.

However, when the sealing width is decreased, it becomesdisadvantageously difficult to ensure the strength of a sealed portion.For solving this problem, it may be required to perform thermal weldingusing a metal block heater having a large heat capacity. When a relatedlaminate film having a general thickness is used, since the interiorresin film 13 has a thickness to a certain extent, even when theelectrode terminal 2 is clamped by the metal block heater in thermalwelding, the resin film 13 may absorb the pressure given thereby.However, when the interior resin film 13 has a small thickness, a largepressure is given particularly to a part of the electrode terminal 2clamped by the metal block heater, and as a result, the electrodeterminal 2 may be sheared or the electrode terminal 2 may penetrate theresin film 13 to cause short-circuiting with the metal foil 11.

Hence, as disclosed in Japanese Unexamined Patent ApplicationPublication No. 2000-348695, when recesses 21 are formed in a metalblock heater 20 at positions corresponding to the electrode terminals 2,and thermal welding is performed while the recesses 21 and the electrodeterminals 2 are being properly positioned, the problem as describedabove may be solved (see FIGS. 4A and 4B).

SUMMARY OF THE INVENTION

However, besides the above problem, other problems may arise when thethickness of the CPP layer is decreased. For example, as shown in FIG.5, short-circuiting may disadvantageously occur between the electrodeterminal 2 and the Al layer when cutting burrs (hereinafter referred toas “burrs” in some cases) 30, which are generated when the laminate film10 is cut, penetrate the CPP layer, resulting in short-circuitingbetween the negative and positive electrode terminals of the cell.

In addition, even when burrs 30 project outside of the cell or are notpresent, if a head portion of a metal block heater 20 applies a pressureto an edge portion of the laminate film 10 in thermal welding,short-circuiting may probably occur.

Hence, in consideration of the problems described above, it is desirableto have a cell having superior safety such that no short-circuitingcaused by burrs and/or pressure application in thermal welding occursand such that no degradation in cycle properties caused by moistureinfiltration occurs.

In order to solve the problems described above, according to anembodiment of the present invention, there is provided a cell having: acell element including a positive electrode having a belt-shaped metalfoil and reaction layers provided on two surfaces thereof, a negativeelectrode having a belt-shaped metal foil and reaction layers providedon two surfaces thereof, and an electrolyte; a laminate film forpackaging the cell element, having a sealing portion and being composedof an exterior resin layer, an interior resin layer, and a metal layerprovided between the exterior layer and the interior resin layer, thesealing portion being thermal welded on a part of the laminate filmapart from an edge portion thereof to form a thermal welded portion forsealing the cell; and electrode terminals electrically connected to thecell element and extending outside through the sealing portion. In thecell described above, a thickness t₂ of the edge portion of the laminatefilm is larger than a thickness t₁ of the thermal welded portion.

In addition, according to another embodiment of the present invention,there is provided a cell having: a cell element including a positiveelectrode having a belt-shaped metal foil and reaction layers providedon two surfaces thereof, a negative electrode having a belt-shaped metalfoil and reaction layers provided on two surfaces thereof, and anelectrolyte; a laminate film for packaging the cell element, having asealing portion and being composed of an exterior resin layer, aninterior resin layer, and a metal layer provided between the exteriorlayer and the interior resin layer, the sealing portion being thermalwelded to form thermal welded portions for sealing the cell; andelectrode terminals electrically connected to the cell element andextending outside through the sealing portion. In the cell describedabove, a thickness t₄ of thermal welded portions including the electrodeterminals is larger than a thickness t₃ of thermal welded portionsincluding no electrode terminals.

According to the embodiments of the present invention, problems can besolved which may arise when a thin laminate film is used as an exteriorpackaging material in order to improve the cell capacity, and a cellhaving superior performance can be obtained in which no short-circuitingoccurs, nor does moisture infiltration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view showing a cell which uses alaminate film as an exterior packaging material;

FIG. 2 is a cross-sectional view of a main structure of a laminate filmas one example;

FIG. 3 is a cross-sectional view showing a cell formed by using anelectrode terminal provided with a sealant for preventing the contactbetween the electrode terminal and a laminate film;

FIGS. 4A and 4B are schematic views for illustrating a thermal weldingmethod for protecting electrode terminals from a large pressure appliedthereto;

FIG. 5 is a schematic view showing the state in which cutting burrs ofAl generated in cutting a laminate film penetrate a resin layer to causeshort-circuiting with an electrode terminal;

FIG. 6 is a schematic perspective view showing one example of a cellelement forming a cell according to an embodiment of the presentinvention;

FIG. 7 is a schematic view showing a contact position of a heater headwhen thermal welding is performed on a part of a laminate film apartfrom an edge portion thereof;

FIG. 8 is a schematic view showing the state in which thermal welding isperformed on a part of a laminate film apart from an edge portionthereof;

FIG. 9 is a cross-sectional view of an electrode terminal portion of acell after thermal welding is performed on a part of a laminate filmapart from an edge portion thereof;

FIG. 10 is a cross-sectional view of a portion of a cell, which includesno electrode terminal, after thermal welding is performed on a part of alaminate film apart from an edge portion thereof;

FIG. 11 is a cross-sectional view of a thermal welded portion obtainedwhen an area of a laminate film which is not in contact with a heaterhead is large;

FIG. 12 is a cross-sectional view of an electrode terminal portion of acell obtained by thermal welding performed on a part of a laminate filmapart from an edge portion thereof, the view showing the state in whichburrs are generated;

FIG. 13 is a schematic view showing a thickness t₃ of a thermal weldedportion including no electrode terminal, a thickness t₄ of a thermalwelded portion including an electrode terminal, a thickness L of theelectrode terminal, and a thickness S of a sealant (one side); and

FIG. 14 is a schematic view showing the state in which a cell element ispackaged in an aluminum laminate film.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, a cell according to an embodiment of the present inventionwill be described in detail.

FIG. 6 shows one example of a cell element forming the cell according tothe embodiment of the present invention. This cell includes a cellelement 40 which is formed of a belt-shaped positive electrode 41, aseparator 43 a, a belt-shaped negative electrode 42 facing the positiveelectrode 41, and a separator 43 b, laminated to each other and wound ina longitudinal direction. In addition, onto two surfaces of each of thepositive electrode 41 and the negative electrode 42, a gel electrolyte44 is applied.

[Positive Electrode]

The positive electrode 41 is formed of a positive electrode collectorand positive electrode active material layers provided on two surfacesthereof, the active material layers containing a positive electrodeactive material. As the positive electrode collector, for example, ametal foil such as an Al foil, a nickel (Ni) foil, or a stainless steelfoil may be used.

The positive electrode active material layer is composed, for example,of a positive electrode active material, a binding agent and aconductive agent. The constituent elements mentioned above are uniformlymixed together to form a positive electrode mixture, and the mixturethus prepared is dispersed in a solvent to form a slurry. Next, thisslurry is uniformly applied onto the positive electrode collector usinga doctor blade method or the like, followed by drying at a hightemperature to remove the solvent, so that the positive electrode activematerial layer is formed. In this embodiment, the positive electrodeactive material, the conductive agent, the binding agent, and thesolvent described above are preferably uniformly mixed together, and themixing ratios thereof may be optionally determined.

As the positive electrode active material, a composite oxide composed oflithium and a transition metal may be used. In particular, for example,LiCoO₂, LiNiO₂, and LiMn₂O₄ may be mentioned. In addition, a solidsolution thereof in which some atoms of the transition metal element arereplaced with other atoms may also be used. For example,LiNi_(0.5)Co_(0.5)O₂ and LiNi_(0.8)Co^(0.2)O₂ may be mentioned.

In addition, as the conductive agent, for example, a carbon materialsuch as carbon black or graphite may be used. As the binding agent, forexample, poly(vinylidene fluoride) or polytetrafluoroethylene may beused. In addition, as the solvent, for example, N-methyl pyrrolidone maybe used.

The positive electrode 41 has a positive electrode terminal (indicatedby an electrode terminal 45 shown in FIG. 6) connected to an electrodeend portion by spot welding or ultrasonic welding. This positiveelectrode terminal is preferably formed of a metal foil or a mesh metal;however, as long as being stable from electrochemical and chemicalpoints of views and having electrical conductivity, any materials otherthan metals may also be used. As a material for the positive electrodeterminal, for example, Al may be mentioned.

[Negative Electrode]

The negative electrode 42 is formed of a negative electrode collectorand negative electrode active material layers provided on two surfacesthereof, the active material layers containing a negative electrodeactive material. As the negative electrode collector, for example, ametal foil such as a copper foil, a Ni foil, or a stainless steel foilmay be used.

For example, the negative electrode active material layer is composed ofa negative electrode active material and, whenever necessary, alsocontains a binding agent and a conductive agent. The constituentelements mentioned above are uniformly mixed together to form a negativeelectrode mixture, and the mixture thus prepared is dispersed in asolvent to form a slurry. Next, this slurry is uniformly applied ontothe negative electrode collector by a doctor blade method or the like,followed by drying at a high temperature to remove the solvent, so thatthe negative electrode active material layer is formed. In thisembodiment, the negative electrode active material, the conductiveagent, the binding agent, and the solvent described above are preferablyuniformly mixed together, and the mixing ratios thereof may beoptionally determined.

As the negative electrode active material, a carbon material or acomposite of a metal-based material and a carbonaceous material may beused, that is capable of doping and dedoping a lithium metal compound,lithium alloy, or lithium. In particular, as the carbon material capableof doping and dedoping lithium, for example, graphite, non-graphitizablecarbon, and graphitizable carbon may be mentioned. As the graphite, forexample, natural graphite and artificial graphite such as mesophasecarbon microbeads, carbon fibers, cokes, and the like may be used. As amaterial forming an alloy with lithium, various types of metals may beused, and among those, tin (Sn), cobalt (Co), indium (In), Al, silicon(Si), and alloys thereof are used in many cases. When a lithium metal isused, a powder thereof is not always necessarily processed together witha binding agent to form a coating film, and a rolled lithium metal sheetmay also be used.

In addition, as the binding agent, for example, poly(vinylidenefluoride) or a styrene-butadiene rubber may be used. In addition, as thesolvent, for example, N-methyl pyrrolidone or methyl ethyl ketone may beused.

In addition, as is the positive electrode 41, the negative electrode 42also has a negative electrode terminal (indicated by the electrodeterminal 45 in FIG. 6) connected to an electrode end portion by spotwelding or ultrasonic welding. This negative electrode terminal ispreferably formed of a metal foil or a mesh metal; however, as long asbeing stable from electrochemical and chemical points of views andhaving electrical conductivity, a material other than metals may also beused. As a material for the negative electrode terminal, for example,there may be mentioned copper or Ni.

The positive electrode terminal and the negative electrode terminalpreferably extend in the same direction; however, as long as theterminals cause no short-circuiting and no degradation in cellproperties, extending directions of the terminals may be optionallyselected. In addition, as long as the positive electrode terminal andthe negative electrode terminal are electrically connected to respectiveconnection places, the places to which the terminals are connected andthe connection method thereof may not be particularly limited to thosedescribed above by way of example.

[Electrolyte]

As an electrolyte, an electrolytic salt and an organic solvent, whichare generally used for a lithium ion cell, may be used, and in addition,a gel electrolyte and an electrolyte solution may both be used.

As a non-aqueous solvent, in particular, there may be mentioned, forexample, ethylene carbonate, propylene carbonate, γ-butyrolactone,dimethyl carbonate, diethyl carbonate, ethyl methyl carbonate, dipropylcarbonate, ethyl propyl carbonate, solvents obtained from the abovecarbonates by replacing a hydrogen atom thereof with a halogen atom. Thesolvents mentioned above may be used alone or in combination at apredetermined mixing ratio.

As the electrolyte salts, an electrolyte salt which is dissolved in theabove non-aqueous solvents may be used. For example, there may bementioned LiPF₆, LiBF₄, LiN(CF₃SO₂)₂, LiN(C₂F₅SO₂)₂, and LiClO₄. As theconcentration of the electrolyte salt, a concentration obtained bydissolving the above salt in the solvent may be used without causing anyproblem; however, the amount of lithium ions is preferably in the rangeof 0.4 to 2.0 moles relative to 1 kg of the non-aqueous solvent.

In the case of a gel electrolyte, the electrolyte solution describedabove is processed with a matrix polymer to form a gel electrolyte. Asthe matrix polymer, a material may be used which can be dissolved in anon-aqueous electrolyte solution composed of the non-aqueous solvent andthe electrolyte salt dissolved therein so as to form a gel electrolyte.As the matrix polymer described above, a polymer containing repeatingunits, such as poly(vinylidene fluoride), polyethylene oxide),polypropylene oxide), poly(acrylonitrile), and poly(methacrylonitrile),may be mentioned by way of example. The polymers mentioned above may beused alone or in combination.

Among those mentioned above as the matrix polymer, particularlypreferable examples are poly(vinylidene fluoride) and a copolymer ofpoly(vinylidene fluoride) incorporating 7.5% or less ofhexafluoropropylene. The polymer described above has a number averagemolecular weight in the range of 5.0×10⁵ to 7.0×10⁵ (500,000 to 700,000)or has a weight average molecular weight in the range of 2.1×10⁵ to3.1×10⁵ (210,000 to 310,000), and the intrinsic viscosity of the polymeris set in the range of 1.7 to 2.1.

[Separator]

A separator is formed of a porous polyolefin film such as polypropyleneor polyethylene or a porous inorganic film such as non-woven ceramicfabrics and may also have a laminate structure composed of at least twoporous films mentioned above. Among those mentioned above, a porous filmmade of polyethylene or polypropylene is most effectively used.

In general, a separator having a thickness of 5 to 50 μm is preferablyused; however, a thickness of 7 to 30 μm is more preferable. When theseparator is excessively thick, since the amount of an active materialis decreased, the cell capacity is decreased, and in addition, currentproperties are degraded due to decrease in ion conductivity. On theother hand, when the separator is excessively thin, mechanical strengthof the film is decreased.

A laminate film for packaging the cell element 40 as described above hasthe cross-sectional structure shown in FIG. 2, so that the cell element40 is covered and sealed with the laminate film having humidityresistance and insulation properties. The electrode terminals 2 areconnected to the respective positive electrode 41 and the negativeelectrode 42 and are clamped at a sealing portion of the laminate filmso as to extend outside.

As a laminate film having suitable properties of forming a highly safetycell although having a small thickness which forms a narrow thermalwelded portion, a preferable laminate film was discovered which has thestructure composed of a nylon or PET film having a thickness of 15±5 μmas an exterior layer, an Al foil having a thickness of 35±5 μm, and aCPP film having a thickness of 30±5 μm as an interior layer. In thisstructure, adhesive layers having a thickness of 2 to 3 μm may beprovided on both sides of the Al foil as shown in FIG. 2.

In this embodiment according to the present invention, as shown in FIG.7, along a side of the laminate film from which the electrode terminalsextend, when thermal welding is performed using a heater head on a partof the laminate film apart from the edge portion thereof, a cell isformed so that the thickness of the edge portion of the laminate film islarger than that at a sealed portion, and hence short-circuiting causedby burrs can be prevented. In addition, by the method described above,short-circuiting which may occur when the heater head is brought intocontact with the edge portion of the laminate film can also beprevented. FIG. 7 is a schematic plan view showing an electrode terminalextension side of the cell element, and a portion A shown by obliquelines is the sealed portion.

FIG. 8 is a schematic view showing the state in which thermal welding isperformed on a part of a laminate film 50 apart from an edge portionthereof using a heater head 56. The laminate film 50 has a three-layeredstructure composed of an Al layer 51, an outermost nylon or PET layer52, and an interior CPP layer 53 and has humidity resistance andinsulation properties. In this embodiment, the thickness of the laminatefilm 50 and the thickness of the CPP layer 53 are represented by t andp, respectively.

FIG. 9 is a cross-sectional view of an electrode terminal portion at theelectrode terminal extension side of the cell thus formed (taken along aline IX-IX shown in FIG. 7). Reference numeral 54 indicates an electrodeterminal, and the electrode terminal 54 is coated with a sealant 55 inorder to improve the adhesion with the CPP layer.

A portion indicated by A is a part of the laminate film on which thermalwelding is performed by the heater head, and a portion indicated by B isthe edge portion of the laminate film on which thermal welding is notperformed by the heater head. Since the portion A is heated andcompressed by the heater head, the CPP is melted to flow to anon-compressed portion (portion B). Hence, the portion B graduallyincreases in thickness from the portion A to the edge portion of thelaminate film. Although not directly heated by the heater head, the CPPof the portion B is melted by heat transmitted from the portion A and isadhered to the electrode terminal or the like in many cases. Even whenthe CPP of the portion B is not adhered to the electrode terminal andthe like, any problems may not occur at all.

In addition, FIG. 10 is a cross-sectional view of a thermal weldedportion including no electrode terminal (taken along a line X-X in FIG.7). A portion indicated by A is a part of the laminate film which isheated and compressed by the heater head, and a portion indicated by Bis a part of the laminate film which is not heated and compressed by theheater head. As is the case shown FIG. 7, since the CPP is melted toflow, the portion B also gradually increases in thickness from theportion A to the edge portion of the laminate film.

When the thickness of the thermal welded portion and the thickness ofthe edge portion of the laminate film are represented by t₁ and t₂,respectively, and as shown in FIG. 8, when the thickness of the laminatefilm 50 and the thickness of the CPP layer are represented by t and p,respectively, the following equations are satisfied.

tx2−px2+5<t ₁ <tx2−5 (μm)

t ₁ <tx2<t ₂ (μm)

In order to prevent short-circuiting, thermal welding is performed sothat the edge portion is not thermal welded, and as a result, thethickness of the edge portion becomes large as compared to that of thethermal welded portion located inside.

Since the CPP melted by heating and compression using the heater headflows to the edge portion of the laminate film, the thickness of thethermal welded portion is decreased as compared to an original thicknessthereof (equivalent to the total thickness of the two laminate films).However, when an excessively large pressure is applied in thermalwelding, the CPP excessively flows out, the amount of a resinresponsible for thermal welding becomes deficient, and the sealingproperties are degraded, so that moisture infiltrates the cell. In thiscase, moisture is reduced in the cell to generate gases, and as aresult, the cell swells. When the thickness of a thermal welded CPPlayer formed after thermal welding is larger than 5 μm, that is, whenthe thickness t₁ of the thermal welded portion is larger than[tx2−px2+5] μm, the amount of the CPP does not become deficient, and asa result, infiltration of moisture can be sufficiently prevented.

In addition, when the thickness t₁ of the thermal welded portion isexcessively large, sealing may not be sufficiently performed in somecases. Also in this case, moisture infiltrates the cell and is reducedtherein to generate gases, and as a result, the cell swells. When thethickness of the thermal welded CPP layer formed after thermal weldingis decreased by 5 μm or less as compared to an original thickness of theCPP layer (equivalent to the total thickness of the two CPP layers), theCPP is not sufficiently melted, and as a result, sealing properties maynot be satisfactory. That is, when the thickness t₁ of the thermalwelded portion is smaller than [tx2−5] μm, the CPP is sufficientlymelted for sealing, and as a result, superior cycle properties can bemaintained.

In addition, since heating and compression are performed by the heaterhead on the part of the laminate film apart from the edge portionthereof, the thickness t₂ of the edge portion of the laminate filmbecomes larger than the thickness t₁ of the thermal welded portion.Hence, short-circuiting can be prevented which occurs when burrsgenerated at the edge portion of the laminate film penetrate thesealant, and in addition, short-circuiting between the Al layer and theelectrode terminal can also be prevented which occurs when the heaterhead is brought into contact with the edge portion of the laminate filmin thermal welding.

In this case, since the heater head does not compress the edge portionof the laminate film, the thickness t₂ will not be decreased smallerthan an original thickness [tx2] μm (equivalent to the total thicknessof the two laminate films) and is increased by a certain level whichcorresponds to the amount of the CPP which is pushed out of the thermalwelded portion. However, when an area of the laminate film with whichthe heater head is not brought into contact is large, the CPP is notpushed to the edge portion of the film, and as a result, across-sectional shape as shown in FIG. 11 may be formed. In this case,using a slide gauge, the thickness t₂ of the edge portion of thelaminate film is measured while the two extending portions shown in FIG.11 are overlapped with each other by fingers or the like. Since beingcompressed, the thickness t₁ of the thermal welded portion is smallerthan tx2, and since the thickness t₂ of the edge portion of the laminatefilm is tx2, t₁<t₂ is satisfied; hence, short-circuiting can beprevented.

By the method described above, even in the case shown in FIG. 12 inwhich burrs 30 are generated, they are blocked by a thick CPP layer, andas a result, a cell can be manufactured in which short-circuiting isunlikely to occur.

In addition, besides the method described above, when the followingmethod is used, a safer cell can be further manufactured.

Since the electrode terminal portion is heated and compressed by a metalheater as is the case in the past, a large pressure is locally appliedto the electrode terminal portion as compared to a pressure applied tothe other part of the thermal welded portion. Accordingly, thermalwelding is performed using a heater head having notches at placescorresponding to the electrode terminals.

In this case, since the heater head having notches is used, thethickness of the laminate film of a thermal welded portion including theelectrode terminal is larger than the thickness of the laminate film ofa thermal welded portion including no electrode terminal. As shown inFIG. 13, when the thicknesses of the laminate film, the CPP layer, theelectrode terminal, and one side of the sealant covering the electrodeterminal are represented by t, p, L, and S, respectively, a thickness t₃of the thermal welded portion including no electrode terminal and athickness t₄ of the thermal welded portion including the electrodeterminal are represented by the following equations, which are thethicknesses obtained when the cell is packaged in the film.

tx2−px2+5<t ₃ <tx2−5 (μm)

tx2−px2+5+(L+S)<t ₄ <tx2−5+(L+S) (μm)

The thickness t₃ of the thermal welded portion including no electrodeterminal and the thickness t₄ of the thermal welded portion includingthe electrode terminal are both decreased smaller than the respectiveoriginal thicknesses thereof since the CPP is melted to flow in thermalwelding which is performed by heating and compression using the heaterhead. When the thickness of a thermal welded CPP layer formed after thethermal welding is larger than 5 μm, that is, the thickness t₃ of thethermal welded portion including no electrode terminal is larger than[tx2−px2+5] μm, the amount of the CPP is not deficient, infiltration ofmoisture can be sufficiently prevented. In addition, when the thicknessof the thermal welded CPP layer formed after the thermal welding isdecreased by 5 μm or less from the original thickness of the CPP layer(equivalent to the total thickness of the two CPP layers), the CPP isnot sufficiently melted, and as a result, the sealing properties are notso superior. That is, when the thickness t₃ of the thermal weldedportion including no electrode terminal is smaller than [tx2−5] μm, theCPP is sufficiently melted so that the sealing is well performed, andhence superior cycle properties can be maintained.

In addition, besides the CPP layer of the thermal welded portionincluding the electrode terminal, the sealant covering the electrodeterminal is also melted, and hence the thickness of the sealant isdecreased. A resin of the sealant flows by thermal welding, and thethickness of the sealant is decreased to approximately one half. Whenthe thickness of the sealant is further decreased, it becomes difficultto prevent the contact between the electrode terminal and the laminatefilm. In addition, when the sealant is not so much melted, thermalwelding between the laminate film and the electrode terminal is notsufficiently performed, and as a result, moisture is liable toinfiltrate the cell.

However, although a large amount of the sealant flows, when the totalthickness together with the CPP is in a predetermined range, the sealingmay be sufficiently performed. In addition, although only a small amountof the sealant is melted, when a large amount of the CPP is melted forsealing, and the total thickness of the sealant and the CPP is in apredetermined range, the sealing may not cause any problems.

As is the case of the thickness t₃ of the thermal welded portionincluding no electrode terminal, when the thickness of the thermalwelded CPP layer formed after the thermal welding is larger than 5 μm,that is, when the thickness t₄ of the thermal welded portion includingthe electrode terminal is larger than [tx2−px2+5+(L+S)], infiltration ofmoisture can be sufficiently prevented. In addition, when the decreasein thickness is less than 5 μm, the sealing properties are notsufficient. That is, when the thickness t₄ of thermal welded portionincluding the electrode terminal is less than [tx2−5+(L+S)], the CPP issufficiently melted, and hence the sealing is sufficiently performed.

In the laminate film used in this embodiment, since the thickness of arelated CPP layer is approximately 45 to 50 μm, the thickness of the CPPlayer is set to 20 to 40 μm. As the thickness of the CPP layer isdecreased, the cell capacity can be increased; however, since the CPPmelted during thermal welding flows to the non-pressurized portion, whenthe CPP layer is excessively thin, the sealing properties are degraded.In consideration of the situations described above, the thickness of theCPP layer is preferably set in the range of 20 to 40 μm.

When the cell is formed as described above, since the pressure is notlocally applied to the electrode terminal, the electrode terminal is notbroken, the electrode terminal does not penetrate the CPP layer, and anecessary amount of the CPP does not flow away; hence, as a result,short-circuiting can be prevented.

The heater head used for thermal welding is not limited to thatdescribed above, and as long as sealing can be performed while the aboveconditions are satisfied, a heater head formed of an optional materialand having an optional shape may be used.

EXAMPLES

Hereinafter, examples of the present invention will be described indetail.

[Formation of Positive Electrode]

First, 92 percent by weight of lithium cobalt oxide (LiCoO2), 3 percentby weight of a poly(vinylidene fluoride) powder, and 5 percent by weightof a graphite powder were uniformly mixed together, and the mixture thusprepared was dispersed in N-methyl pyrrolidone, so that a positiveelectrode mixture in the form of a slurry was obtained. This positiveelectrode mixture was uniformly applied to two surfaces of an Al foilused as a positive electrode collector, followed by vacuum drying at100° C. for 24 hours, so that a positive electrode active material layerwas formed.

Next, after a positive electrode sheet was formed by compression moldingof the positive electrode active material layer using a rollercompression machine and was then cut into a belt-shaped positiveelectrode having a width of 50 mm and a length of 300 mm, an Al ribbonwas welded as the electrode terminal to a part of the positive electrodewhich was not coated with the active material. In addition,polypropylene sheets were adhered to two surfaces of the electrodeterminal to be held by an aluminum laminate film.

[Formation of Negative Electrode]

First, 91 percent by weight of artificial graphite and 9 percent byweight of a poly(vinylidene fluoride) powder were uniformly mixedtogether, and the mixture thus prepared was dispersed in N-methylpyrrolidone, so that a negative electrode mixture in the form of aslurry was obtained. This negative electrode mixture was uniformlyapplied to two surfaces of a copper foil used as a negative electrodecollector, followed by vacuum drying at 120° C. for 24 hours, so that anegative electrode active material layer was formed.

Next, after a negative electrode sheet was formed by compression moldingof the negative electrode active material layer using a rollercompression machine and was then cut into a belt-shaped negativeelectrode having a width of 52 mm and a length of 320 mm, a Ni ribbonswas welded as the electrode terminal to a part of the negative electrodewhich was not coated with the active material. In addition,polypropylene sheets were adhered to two surfaces of the electrodeterminal to be held by the aluminum laminate film.

[Formation of Gel Electrolyte]

A poly(vinylidene fluoride) copolymer including 6.9% ofhexafluoropropylene, a non-aqueous electrolyte solution, and dimethylcarbonate (DMC) as a dilution solvent were mixed, stirred, and dissolvedinto each other, so that a sol electrolyte solution was obtained. Theelectrolyte solution was formed by dissolving 0.8 moles of LiPF₆ and 0.2moles of LiBF₄ into a mixed solvent relative to 1 kg thereof, the mixedsolvent being composed of ethylene carbonate and propylene carbonate ata mixing ratio of 6 to 4 on a weight basis. The mixing ratio among thepoly(vinylidene fluoride) copolymer, electrolyte solution, and DMC wereset to 1:6:12 on a weight basis. Next, the sol electrolyte solution thusobtained was uniformly applied onto two surfaces of each of the positiveelectrode and the negative electrode. Subsequently, the solvent wasremoved by drying at 50° C. for 3 minutes, gel electrolyte layers wereformed on the two surfaces of each of the positive electrode and thenegative electrode.

[Formation of Test Cell]

The belt-shaped positive electrode provided with the gel electrolytelayers on the two surfaces thereof and the belt-shaped negativeelectrode provided with the gel electrolyte layers on the two surfacesthereof were wound in the longitudinal direction with a separatorprovided therebetween, so that a cell element was obtained. As theseparator, a porous polyethylene film having a thickness of 10 μm and aporosity of 33% was used.

Finally, as shown in FIG. 14, a cell element 60 was packaged in analuminum laminate film 61 composed of an Al foil provided between tworesin films, and thermal welding was performed along the peripheralportion of the aluminum laminate film 61 under vacuum conditions, sothat sealing was performed. The width of a terrace portion (A+B shown inFIGS. 7, 9, and 10) of the cell was formed so as to be approximately 2.5mm.

By using the test cells thus formed, the following were evaluated.

Example 1

Cells of Examples 1-1 to 1-3 and Comparative Examples 1-1 to 1-7 wereformed by changing the width of the heater head, and in addition, thetemperature of the heater head and the pressure in thermal welding werealso changed, so that the thickness t₁ of the thermal welded portion andthe thickness t₂ of the edge portion of the laminate film were changed.The cells of Examples 1-1 to 1-3 and Comparative Examples 1-1 and 1-2were formed by using a heater head having a width of 2.0 mm, the cellsof Comparative Examples 1-3 to 1-7 were formed using a heater headhaving a width of 3.0 mm, and for exterior packaging of each cell, analuminum laminate film having a thickness of 85 μm was used, the filmbeing composed of a nylon layer 15 μm thick, an adhesive layer 3 μmthick, an aluminum layer 35 μm thick, an adhesive layer 2 pun thick, anda CPP layer 30 μm thick in that order from the outer side. In addition,as the electrode terminal, an aluminum ribbon 4 mm wide and 70 μm thickwas used, and onto the two surfaces of the electrode terminal to be heldby the aluminum laminate film, polypropylene sheets 6 mm wide and 50 μmthick were adhered.

In the case in which the laminate film as described above is used, thethickness of the thermal welded portion is 110 μm when all the CPP islost, and the thickness of the thermal welded portion is 170 μm when itis not compressed at all and is further increased when a resin flowsthereto from another portion.

When the thickness of the thermal welded portion, the thickness of theedge portion of the laminate film, the thickness of the laminate film,and the thickness of the CPP layer are represented by t₁, t₂, t, and p,respectively, and when the thickness t₁ of thermal welded portion andthe thickness t₂ of the edge portion of the laminate film satisfy thefollowing equations, short-circuiting caused by burrs, short-circuitingbetween the Al layer of the laminate film and the electrode terminalcaused by pressure application by the heater head, and gas generationcaused by moisture infiltration can be prevented.

tx2−px2+5<t ₁ <tx2−5 (μm)

t ₁ <tx2<t ₂ (μm)

Hence, in the case of the laminate film used this time, when 115μm<t1<165 μm and t₂≥170 μm are satisfied, a practically usable cell canbe obtained.

In Table 1 below, the thickness t₁ of the thermal welded portion of thecell, the thickness t₂ of the edge portion of the laminate film, and thewidth of the heater head of each of Examples 1-1 to 1-3 and ComparativeExamples 1-1 to 1-7 are shown. In addition, the upper limit and thelower limit of the thickness of the thermal welded portion describedabove are also shown in Table 1. Of the thickness t1 of the thermalwelded portion and the thickness t₂ of the edge portion of the laminatefilm shown in the table, values with underlines are out of theappropriate ranges.

TABLE 1 Thermal Thickness Thermal Welded Welded Heater Edge Film p ofCPP Portion Portion Head Portion Thickness t Layer Upper Lower Film x t₁Width t₂ (μm) (μm) Limit Limit 2 (μm) (mm) (μm) Example 1-1 85 30 115165 170 120 2.0 220 Example 1-2 85 30 115 165 170 140 2.0 190 Example1-3 85 30 115 165 170 160 2.0 170 Comparative 85 30 115 165 170 110 2.0230 Example 1-1 Comparative 85 30 115 165 170 168 2.0 170 Example 1-2Comparative 85 30 115 165 170 110 3.0 110 Example 1-3 Comparative 85 30115 165 170 120 3.0 120 Example 1-4 Comparative 85 30 115 165 170 1403.0 140 Example 1-5 Comparative 85 30 115 165 170 160 3.0 160 Example1-6 Comparative 85 30 115 165 170 168 3.0 168 Example 1-7

Ten test cells as described above were formed in each Example and eachComparative Example, and the number of cells which causedshort-circuiting was measured. In addition, for cells which did notcause short-circuiting, cell swelling (increase in thickness) (mm)caused by gas generation inside the cell and cycle properties (%) weremeasured.

In order to detect short-circuiting, the resistance between the positiveelectrode and the negative electrode was measured. A cell right afterassembly has enough high series resistance, and when short-circuitingoccurs, the resistance is decreased to a level of a milliohm order. Ascauses of short-circuiting, for example, the case may be mentioned inwhich the electrode terminal or burrs thereof penetrate the innermostCPP layer of the aluminum laminate film used as an exterior packagingmaterial and reach the Al foil layer.

On the other hand, when a large pressure is applied to the portionincluding no electrode terminal in thermal welding, the CPP flows, thesealing properties are degraded, and as a result, moisture infiltratesthe cell. In this case, moisture is reduced in the cell to generategases, so that the cell swells. Although the cell may swell due to thepresence of moisture in the electrolyte in some cases, the swelling isnot significant. The thickness of a cell after assembly and firstcharging was measured, and when the increase in thickness was 0.1 mm ormore, the cell was regarded as a defective product, and when thethickness was less than 0.1 mm, the cell was regarded as a good product.

Furthermore, regardless whether the thermal welded portion includes theelectrode terminal or not, when the thickness of the thermal weldedportion is excessively large, sealing may not be sufficiently performedin some cases. In this case, moisture infiltrates the cell and is thenreduced to generate gases, and as a result, the cell swells. As is thecase described above, after the thickness of a cell after assembly andfirst charging was measured, when the increase in thickness was 0.1 mmor more, the cell is regarded as a defective product, and when thethickness was less than 0.1 mm, the cell was regarded as a good product.

For measurement of the cycle properties, standard charging and 1C-3Vcut-off constant current discharging were carried out, and the change indischarging capacity was measured for each cycle. In this example, amaintenance rate of capacity after 500 cycles was examined, and a cellhaving a maintenance rate of 80% or more was regarded as a good product.The maintenance rate of 80% or more is a value which is believed to begenerally required and sufficient for the specification of a currentportable electronic apparatus. When moisture infiltrates the cell, dueto side reactions, the cycle properties are degraded. The cycleproperties are calculated by the following equation.

Cycle Properties=100×(Discharging Capacity at 500th cycle)/(DischargingCapacity at first cycle) (%)

The structures of the cells of the individual examples and the resultsof the above evaluations are shown in Table 2. Of the thickness t₁ ofthe thermal welded portion and the thickness t₂ of the edge portion ofthe laminate film shown in the table, values with underlines are out ofthe appropriate ranges.

TABLE 2 Number of Cells Thermal Heater Causing Gas Cycle Welded HeadEdge Short- Swell- Prop- Portion t₁ Width Portion Circuiting ing erties(μm) (mm) (μm) (Cells) (mm) (%) Example 1-1 120 2.0 220 0 0.02 88Example 1-2 140 2.0 190 0 0.03 85 Example 1-3 160 2.0 170 0 0.02 86Comparative 110 2.0 230 10 — — Example 1-1 Comparative 168 2.0 170 00.23 72 Example 1-2 Comparative 110 3.0 110 10 — — Example 1-3Comparative 120 3.0 120 10 — — Example 1-4 Comparative 140 3.0 140 10 —— Example 1-5 Comparative 160 3.0 160 10 — — Example 1-6 Comparative 1683.0 168 0 0.22 68 Example 1-7

As apparent from the above table, in the cells of Examples 1-1 to 1-3 inwhich the heater head having a width of 2.0 mm which was smaller thanthe width of the terrace portion was used, when thermal welding wasperformed on a part of the laminate film apart from the edge portionthereof, the thickness t₁ of the thermal welded portion was in apredetermined range (115<t₁<165 (μm)), and the thickness t₂ of the edgeportion of the laminate film was larger than the thickness t1 of thethermal welded portion. As a result, no short-circuiting occurred, noswelling was observed, and hence superior cycle properties wereobtained.

On the other hand, although the heater head having a width smaller thanthe width of the terrace portion was used, and thermal welding wasperformed on a part of the laminate film apart from the edge portionthereof, when the thickness t1 of the thermal welded portion was not ina predetermined range, the test cell thus obtained did not work well. InComparative Example 1-1, although the heater head having a width of 2.0mm was used, and the thickness t₁ of the thermal welded portion wasdecreased to 110 μm, since sealing was performed by applying anexcessively large pressure, the electrode terminal was broken, and as aresult, short-circuiting occurred. In addition, in Comparative Example1-2, although the heater head having a width of 2.0 mm was used, and thethickness t₁ of the thermal welded portion was increased to 168 μm,since sealing was performed by applying an excessively small pressure,the sealing properties were not sufficient, moisture infiltrated thecell, and as a result, gas swelling occurred.

Furthermore, as in Comparative Examples 1-3 to 1-6, when the heater headhaving a width of 3.0 mm was used, since the edge portion of thelaminate film was compressed by the heater head, the electrode terminaland the Al layer caused short-circuiting, or burrs thereof penetratedthe CPP layer and caused short-circuiting with the electrode terminal.In addition, as in Comparative Example 1-7, when the sealing wasperformed using the heater head having a width of 3.0 mm by applying asmall pressure, no short-circuiting occurred; however, since thethickness t₁ of the thermal welded portion and the thickness t₂ of theedge portion of the laminate film were large, moisture infiltrated thecell to generate gases, and besides cell swelling, the cycle propertieswere degraded.

As described above, when the thickness of the edge portion of thelaminate film is set larger than the thickness of the thermal weldedportion, a cell can be manufactured in which no short-circuiting occurs,nor does swelling caused by gases.

Example 2

By changing the structure of the laminate film used as an exteriorpackaging material for the cell element and the temperature and pressureof the heater head in thermal welding, the thickness t₃ of the thermalwelded portion and the thickness t₄ of the electrode terminal portionwere changed, so that various test cells were formed. As the laminatefilm used as an exterior packaging material, one of the followinglaminate films was used. That is, there was used an aluminum laminatefilm having a total thickness of 85 μm composed of a 15 μm-thickoutermost nylon layer, 3 μm-thick adhesive layer, 35 μm-thick aluminumfoil, 2 μm-thick adhesive layer, and 30 μm-thick CPP layer or analuminum laminate film having a total thickness of 75 μm, which had thesame structure as that described above except that the thickness of theCPP layer was 20 μm (15 μm-thick nylon layer, 3 μm-thick adhesive layer,35 μm-thick aluminum foil, 2 μm-thick adhesive layer, and 20 μm-thickCPP layer). In addition, a heater head having a width of 2.0 mm was usedwhen the side from which the electrode terminal extended was thermalwelded, and the width of a sealed portion including a part adhered tothe electrode terminal or the like by heat transmitted from the thermalwelded portion was set to 2.2 mm.

An Al ribbon having a width of 4 mm and a thickness of 70 μm was used asthe electrode terminal of each of cells of Examples 2-1 to 2-14 andComparative Examples 2-1 to 2-12, and polypropylene sheets each having awidth of 6 mm and a thickness of 50 μm were adhered onto two surfaces ofa part of the electrode terminal to be held by the aluminum laminatefilm. In addition, in Examples 2-15 and 2-16 and Comparative Examples2-13 to 2-16, an Al ribbon having a width of 4 mm and a thickness of 100μm was used as the electrode terminal, and polypropylene sheets eachhaving a width of 6 mm and a thickness of 60 μm were adhered onto twosurfaces of a part of the electrode terminal to be held by the aluminumlaminate film.

In Example 2, in the case in which the laminate film having a totalthickness of 85 μm is used, when all the CPP layer is lost, thethickness of the thermal welded portion is 110 μm, and the thickness ofthe thermal welded portion is 170 μm when the laminate film is notcompressed at all and is further increased when a resin flows theretofrom another portion.

In addition, when the laminate film having a total thickness of 75 μm isused, the thickness of the thermal welded portion is 110 μm when all theCPP is lost, the thickness of the thermal welded portion is 150 μm whenthe laminate film is not compressed at all and is further increased whena resin flows thereto from another portion.

When the thicknesses of the thermal welded portion including noelectrode terminal, the thermal welded portion including the electrodeterminal, the laminate film, the CPP layer, the electrode terminal, andone side of the sealant covering the electrode terminal are representedby t₃, t₄, t, p, L, and S, respectively, and when the thickness t₃ ofthe thermal welded portion including no electrode terminal and thethickness t₄ of the thermal welded portion including the electrodeterminal satisfy equations shown below, which are the thicknessesobtained when the cell is packaged in the film, the following effectscan be obtained.

tx2−px2+5<t ₃ <tx2−5 (μm)

tx2−px2+5+(L+S)<t ₄ <tx2−5+(L+S) (μm)

That is, short-circuiting caused by burrs, short-circuiting between theAl layer of the laminate film and the electrode terminal caused bypressure applied by the heater head, and gas generation caused bymoisture infiltration can be prevented. Hence, a practically usable cellcan be obtained when the following conditions are satisfied in theindividual Examples and Comparative Examples.

(1) In the case in which the laminate film having a total thickness of85 μm, the electrode terminal having a thickness of 70 μm, and thesealant having a thickness (one side) of 50 μm are used (Examples 2-1 to2-12 and Comparative Examples 2-1 to 2-8), 115 μm<t_(3<165) μm and 235μm<t_(4<285) μm are satisfied.

(2) In the case in which the laminate film having a total thickness of75 μm, the electrode terminal having a thickness of 70 μm, and thesealant having a thickness (one side) of 50 μm are used (Examples 2-13and 2-14 and Comparative Examples 2-9 to 2-12), 115 μm<t₃<145 μm and 235μm<t₄<265 μm are satisfied.

(3) In the case in which the laminate film having a total thickness of85 μm, the electrode terminal having a thickness of 100 μm, and thesealant having a thickness (one side) of 60 μm are used (Examples 2-15and 2-16 and Comparative Examples 2-13 to 2-16), 115 μm<t₃<165 μm and275 μm<t₄<325 μm are satisfied.

In Table 3 below, the thickness of the laminate film, the thickness ofthe CPP layer, the thickness t₃ of the thermal welded portion includingnot electrode terminal, and the thickness t₄ of the thermal weldedportion including the electrode terminal are shown. Of the thickness t₃and the thickness t₄ shown in the table, values with underlines are outof the appropriate ranges described above. In addition, in Table 3, thethickness t₃ of the thermal welded portion including no electrodeterminal and the thickness t₄ of the thermal welded portion includingthe electrode terminal are represented by a thermal welded part and anelectrode terminal part, respectively, and the upper limits and thelower limits of the thermal welded part and the electrode terminal partare also shown.

TABLE 3 Thermal Thermal Thickness Welded Electrode Welded Edge Film p ofCPP Portion Terminal Part Portion Portion Thickness t Layer Upper LowerLower Upper t₃ t₄ (μm) (μm) Limit Limit Limit Limit (μm) (μm) Example2-1 85 30 115 165 235 285 117 240 Example 2-2 85 30 115 165 235 285 140240 Example 2-3 85 30 115 165 235 285 162 240 Example 2-4 85 30 115 165235 285 117 270 Example 2-5 85 30 115 165 235 285 140 270 Example 2-6 8530 115 165 235 285 162 270 Example 2-7 85 30 115 165 235 285 120 245Example 2-8 85 30 115 165 235 285 120 260 Example 2-9 85 30 115 165 235285 120 275 Example 2-10 85 30 115 165 235 285 150 245 Example 2-11 8530 115 165 235 285 150 260 Example 2-12 85 30 115 165 235 285 150 275Example 2-13 75 20 115 145 235 265 120 240 Example 2-14 75 20 115 145235 265 120 240 Example 2-15 85 30 115 165 275 325 140 300 Example 2-1685 30 115 165 275 325 140 300 Comparative 85 30 115 165 235 285 112 240Example 2-1 Comparative 85 30 115 165 235 285 168 240 Example 2-2Comparative 85 30 115 165 235 285 112 270 Example 2-3 Comparative 85 30115 165 235 285 168 270 Example 2-4 Comparative 85 30 115 165 235 285120 220 Example 2-5 Comparative 85 30 115 165 235 285 120 300 Example2-6 Comparative 85 30 115 165 235 285 150 220 Example 2-7 Comparative 8530 115 165 235 285 150 300 Example 2-8 Comparative 75 20 115 145 235 265102 240 Example 2-9 Comparative 75 20 115 145 235 265 148 240 Example2-10 Comparative 75 20 115 145 235 265 120 210 Example 2-11 Comparative75 20 115 145 235 265 120 270 Example 2-12 Comparative 85 30 115 165 275325 112 300 Example 2-13 Comparative 85 30 115 165 275 325 168 300Example 2-14 Comparative 85 30 115 165 275 325 140 260 Example 2-15Comparative 85 30 115 165 275 325 140 340 Example 2-16

Ten test cells as described above were formed in each Example and eachComparative Example, and the number of cells which causedshort-circuiting was measured. In addition, for cells which did notcause short-circuiting, cell swelling (increase in thickness) (mm)caused by gas generation inside the cell and cycle properties (%) weremeasured. The measurement methods thereof are the same as those inExample 1.

In Table 4 below, the structures of the cells of the individual examplesand the results of the above tests are shown. In addition, of thethickness t₃ of the thermal welded portion including no electrodeterminal and the thickness t₄ of the thermal welded portion includingthe electrode terminal shown in the table, values with underlines areout of the appropriate ranges. In addition, in Table 4, the thickness ofthe thermal welded portion including no electrode terminal and thethickness of the thermal welded portion including the electrode terminalare represented by t₃ of the thermal welded part and t₄ of the electrodeterminal part, respectively.

TABLE 4 Number of Thermal Electrode Cells Causing Welded Terminal Short-Gas Part t₃ Part t₄ Circuiting Swelling Cycle (μm) (μm) (cells) (mm)Properties (%) Example 2-1 117 240 0 0.03 85 Example 2-2 140 240 0 0.0284 Example 2-3 162 240 0 0.03 85 Example 2-4 117 270 0 0.02 84 Example2-5 140 270 0 0.02 88 Example 2-6 162 270 0 0.02 86 Example 2-7 120 2450 0.02 86 Example 2-8 120 260 0 0.02 84 Example 2-9 120 275 0 0.03 86Example 2-10 150 245 0 0.02 85 Example 2-11 150 260 0 0.03 83 Example2-12 150 275 0 0.02 84 Example 2-13 120 240 0 0.02 85 Example 2-14 120240 0 0.03 85 Example 2-15 140 300 0 0.03 84 Example 2-16 140 300 0 0.0286 Comparative 112 240 0 0.17 75 Example 2-1 Comparative 168 240 0 0.1872 Example 2-2 Comparative 112 270 0 0.16 77 Example 2-3 Comparative 168270 0 0.17 75 Example 2-4 Comparative 120 220 10 — — Example 2-5Comparative 120 300 0 0.18 73 Example 2-6 Comparative 150 220 10 — —Example 2-7 Comparative 150 300 0 0.19 71 Example 2-8 Comparative 102240 10 — — Example 2-9 Comparative 148 240 0 0.20 69 Example 2-10Comparative 120 210 10 — — Example 2-11 Comparative 120 270 0 0.22 63Example 2-12 Comparative 112 300 10 — — Example 2-13 Comparative 168 3000 0.21 66 Example 2-14 Comparative 140 260 10 — — Example 2-15Comparative 140 340 0 0.23 68 Example 2-16

As apparent from the above table, when the thickness of the thermalwelded portion including the electrode terminal is appropriately largerthan the thickness of the thermal welded portion including no electrodeterminal, a cell having superior properties can be formed. Examples 2-1to 2-16 shown in the table are the examples described above.

As a defective product, for example, a cell may be mentioned in whichthe thickness of the thermal welded portion including no electrodeterminal is large. In this case, since the cross-sectional area of amoisture-infiltrating path is increased, and infiltrating moisture isturned into gases in the cell, the cell may swell or the cycleproperties thereof may be degraded. For example, the above problems maybe observed in Comparative Examples 2-2, 2-4, and 2-14. In the thermalwelded portion including no electrode terminal, the total thickness is170 μm when two parts of the laminate film are overlapped; however, inComparative Examples 2-2, 2-4, and 2-14, the thickness after the thermalwelding is 168 μm, and the CPP layer is not sufficiently melted, so thatthe sealing is not satisfactorily performed. Hence, moisture infiltratesthe cell, and gases are generated, so that the gas swelling is largesuch as 0.18, 0.17, and 0.21 mm in Comparative Examples 2-2, 2-4, and2-14, respectively.

On the other hand, when the thermal welded portion including noelectrode terminal is excessively thin, a defective cell may be formed.For example, in Comparative Examples 2-1 and 2-3, the thickness t₃ ofthe thermal welded portion including no electrode terminal is 112 μm.Since the total thickness is 170 μm when the laminate films is foldedand two parts thereof are overlapped, and the CPP film of each of theabove two parts has a thickness of 30 μm, even when the CPP film is allmelted and flows out, a total thickness of 110 μm is to be obtained.That is, since the thickness of a thermal welded CPP layer obtainedafter melting and flowing in Comparative Examples 2-1 and 2-3 becomesvery small such as 2 μm, and the amount of a resin responsible foradhesion is not sufficient, moisture infiltrates the cell, and the cellproperties are degraded.

Furthermore, for example, as is the case of Comparative Examples 2-5 and2-7, when the thickness t₄ of the thermal welded portion including theelectrode terminal is excessively small, the electrode terminal causesshort-circuiting, and a cell may not be formed. In addition, forexample, as is the case of Comparative Examples 2-6 and 2-7, when thethickness t₄ of the thermal welded portion including the electrodeterminal is excessively large, moisture infiltrates the cell, and hencethe cycle properties are degraded.

As described above, in consideration of the probability ofshort-circuiting and insufficient sealing properties, which may occurwhen a thin laminate film is used in order to improve the cell capacity,when the method for forming a cell, as described above, is used, a cellhaving superior safety and high performance can be obtained.

Heretofore, one embodiment of the present invention has been describedin detail; however, the present invention is not limited to the aboveembodiment, and various modifications may be made without departing fromthe spirit and the scope of the present invention.

For example, in the above embodiment, the case is described in which thebelt-shaped positive and negative electrodes which are laminated withthe separator provided therebetween are wound in the longitudinaldirection to form an electrode body as the cell; however, the presentinvention is not limited thereto and may be applied to a laminatedelectrode body composed of the positive electrode and the negativeelectrode laminated to each other or a folded electrode body in whichthe positive and negative electrodes are not wound but are foldedseveral times.

In addition, the shape of the cell of the embodiment described above maybe cylinder, square, and the like and is not particularly limited, andin addition, various sizes, such as thin type and large type cells, maybe optionally formed.

It should be understood by those skilled in the art that variousmodifications, combinations, sub-combinations and alterations may occurdepending on design requirements and other factors insofar as they arewithin the scope of the appended claims or the equivalents thereof.

What is claimed is:
 1. A method of forming a package, comprising:providing two laminate edge portions of the package, each of whichincludes a foil layer between first and second resin layers such thatthe respective first resin layers face each other and the respectivesecond resin layers face away from each other and such that edges of theedge portions are in registration; and welding together the respectivefirst resin layers at a first position spaced apart from the edges whilenot welding the respective first resin layers at the edges such that,given a thickness of each laminate edge portion before being subjectedto heat and compression is represented by t, a thickness of laminateportions at the first position is represented by t₁, and a thickness oflaminate portions at the edges thereof is represented by t₂, then,t₁<2t<t₂, wherein the edge portions include edges from which electrodeterminals extend such that portions of the electrode terminals areexposed beyond the edges, and wherein the edge portions are between asealing portion and exposed portions of positive and negative electrodeterminals.
 2. The method of claim 1, wherein the welding is ultrasonicwelding.
 3. The method of claim 1, wherein the welding uses anapplication of heat and compression.
 4. The method of claim 3, whereinthe application of heat comprises using a heater head with notches in asurface thereof to accommodate electrodes of a battery cell.
 5. Themethod of claim 1, further comprising: enclosing a battery cell in thepackage prior to subjecting the laminate edge portions of the package towelding.
 6. The method of claim 1, wherein during welding, portions ofthe respective first resin layers flow toward the edges such that t₂ isgreater than or equal to 2t.
 7. The method of claim 1, wherein therespective first resin layers include cast polypropylene.
 8. The methodof claim 1, wherein the foil layer includes aluminum, the respectivefirst resin layers include cast polypropylene, and the respective secondresin layers include nylon or poly(ethylene terephthalate).
 9. Themethod of claim 1, wherein a relationship in which 2t−2p+5<t₁<2t−5 inunit of micrometer is satisfied, and wherein p represents a thickness ofeach first resin layer prior to welding.